Square wire manufacturing machine

ABSTRACT

For providing a thin square wire being used for a coil in low cost and for forming a square hole for press-forming a square wire accurately and easily, a square wire manufacturing machine comprises a four rollers  1 - 4  being disposed in a shape of swastika to be crossed mutually for forming a square hole  5  and a position adjusting unit for adjusting disposed positions of the four rollers. A wedge-slide-type position adjusting mechanism is applied to the position adjusting unit. The wedge-slide-type position adjusting mechanism fine-adjusts the disposed position of respective rollers  1 - 4  to move each roller  1 - 4  in a direction of an axis thereof and in a direction perpendicular to the axis thereof.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to a square wire manufacturing machine forforming a thin square wire, which is used for a thin motor, a thintransformer, an electrical apparatus such as a voice coil for a highperformance speaker or an electronic equipment, with a round conductivewire.

[0003] 2. Description of the Related Art

[0004] When a usual round conductive wire (circular section) is woundfor a coil used in a thin motor or a speaker voice coil, gaps betweenconductive wires and swelling on a crossing area of conductive wiresresult to be problems for miniaturization or dimensional accuracy ofelectronic components. In all electronic components which givesmechanical vibration or rotation by an interaction of a magnetic fieldand a generated magnetic field by electric current of an inductive wirein the magnetic field, improvement of performance and miniaturization ofan inductive wire wound for a coil are required.

[0005] Manufacturing a long thin square wire is required to solve theabove problems. The square wire herein includes a regular square wire.

[0006] Regarding usual methods of manufacturing a square wire, rolling around wire to a rectangular-section wire by a pressure roll or drawing around conductive wire through a draw die having a square hole are known.

[0007] Objects to be Solved

[0008] However, usual method of manufacturing a square wire mentionedabove result always round portions (curved surface) on corners of thesquare wire. Therefore, when a coil is wound with a square wiremanufactured by a usual method, gaps (smaller than gaps with a roundconductive wire) between conductive wires still result.

[0009] According to a method of rolling a round conductive wire by apressure roll, round portions on corners always arise and shapes of theround portions are not uniform. Furthermore, deformation of the wire ordispersion of a wire diameter may be occurred easily.

[0010] When a square wire is made of a thin conductive sheet metal,length of the thin sheet metal as a base material is limited to competeagainst a round conductive wire. More complex manufacturing machine orcost-up may be concerned. The length of a base material is short so thatsupplying a thin sheet metal is required at frequent intervals and thencontinuous automatic operation of a winding machine may be hindered.

[0011] To overcome the above drawback of prior art, one object of thisinvention is to provide a square wire manufacturing machine which canmanufacture a conductive wire, having a square section and being usedfor a coil, continuously and precisely in low-cost with a relativelysimple structure.

SUMMARY OF THE INVENTION

[0012] How to Attain the Object

[0013] In order to attain the objects, a square wire manufacturingmachine, according to the invention, includes four rollers beingdisposed in a shape of swastika to be crossed mutually for forming asquare hole and a position adjusting unit for adjusting disposedpositions of the four rollers.

[0014] Furthermore, the position adjusting unit mentioned above includesa fixed wedge portion and a movable wedge portion contacting with thefixed wedge portion continuously with pressure and being disposedasymmetrically against the fixed wedge portion. And the movable wedgeportion is mounted on a bearing unit of the roller.

[0015] Furthermore, the position adjusting unit mentioned above includesa first position adjusting device for adjusting a disposed position ofthe roller to move the roller in a direction of an axis of rotation ofthe roller and a second position adjusting device for adjusting adisposed position of the roller to move the roller in a directionperpendicular to the axis of rotation. And both the first and the secondposition adjusting devices are mounted on the bearing units ofrespective four rollers.

[0016] Furthermore, the position adjusting unit mentioned aboveincluding a first position adjusting means for adjusting and fixing adisposed position of a first roller of the four rollers, a secondposition adjusting means for adjusting a gap against the first roller tomove a disposed position of a second roller in a direction of an axis ofrotation of the second roller and adjusting a forming size of the squarewire to move a disposed position of the second roller in a directionperpendicular to the axis of rotation of the second roller and fixingthe second roller, a third position adjusting means for adjusting a gapagainst the second roller to move a disposed position of a third rollerin a direction of an axis of rotation of the third roller and adjustingthe forming size of the square wire to move a disposed position of thethird roller in a direction perpendicular to the axis of rotation of thethird roller and fixing the third roller, and a fourth positionadjusting means for adjusting the forming size of the square wire tomove a disposed position of a fourth roller in a direction of an axis ofrotation of the fourth roller and adjusting a gap against the firstroller to move a disposed position of the fourth roller in a directionperpendicular to the axis of rotation of the fourth roller and fixingthe fourth roller is effective.

[0017] Preferably, the four rollers being disposed in a shape ofswastika to be crossed mutually for forming a square hole and fourrotation transmitting devices including motors for driving respectivelythe four rollers are placed in the shape of swastika around the hole.

[0018] According to this invention, a long square wire can bemanufactured by forwarding a round wire through a square hole beingformed with four rollers so that an accurate square wire can be formedin high speed. The disposed positions of the four rollers can beadjusted freely and then a thin square wire can be manufactured easilyand precisely.

[0019] Furthermore, according to this invention, a long square wire canbe formed by a relatively simple machine having four rollers so thatcost of a manufacturing machine can be reduced and number ofinterruption in process is remarkably reduced. Therefore,manufacturability for a square wire is improved and manufacturing costof a square wire is reduced. When the four rollers are worn away, thefour rollers can be reused to be re-polished so that manufacturing costcan be reduced.

[0020] According to this invention, disposed positions of the fourrollers can be moved freely in a very small quantity so that formingaccuracy of a square wire can be improved and also a thin square wirecan be formed easily and precisely.

[0021] According to this invention, disposed positions of the fourrollers can be adjusted both in a direction of an axis and in adirection perpendicular to an axis so that the shape of the square holebeing formed by the four rollers can be fine-adjusted easily. Therefore,accuracy of the square hole for press-forming a round wire can be muchimproved and a thin accurate square wire can be formed continuously.

[0022] According to this invention, operation for disposing the fourrollers in position can be easily, quickly and effectively done. And asquare hole can be easily structured to form various size of squarewires, for example from a 1.5 mm square wire to a 0.02 mm extra-thinsquare wire.

[0023] According to this invention, a whole physical size of a squarewire manufacturing machine can be miniaturized so that the foot-printsize can be reduced and manufacturing cost can be reduced. The machinecan be miniaturized so that multiple-step can be constituted by aplurality of square wire manufacturing machines which have respectivegradually decreased square holes being formed by the four rollers andforwarding a round wire through the multiple-step holes, a extra-thinand very accurate square wire can be manufactured.

[0024] The above and other objects and features of this invention willbecome more apparent from the following description taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025]FIG. 1 is a plan view, showing a layout with main components of anembodiment of a square wire manufacturing machine according to thisinvention;

[0026]FIG. 2 is a side view, showing main area of a position adjustingunit of the embodiment of the square wire manufacturing machineaccording to this invention;

[0027]FIG. 3 is a plan view of main area of a position adjusting unitshown in FIG. 2; and

[0028]FIG. 4 is an explanation drawing of operation, showing arelationship between four rollers and position adjusting units beingused in the embodiment of the square wire manufacturing machineaccording to this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] An embodiment according to this invention will now be describedwith reference to figures. FIGS. 1-4 show a square wire manufacturingmachine according to an embodiment of this invention. The square wiremanufacturing machine is structured to have a square wire (including aregular square wire) by press-forming a circular section roundconductive wire (metal wire) into square.

[0030]FIG. 1 shows main components constituting the square wiremanufacturing machine. The square wire manufacturing machine includesfour rollers which are a first roller 1, a second roller 2, a thirdroller 3 and a fourth roller 4. The first roller 1, the second roller 2,the third roller 3 and the fourth roller 4 are disposed in a shape ofswastika to be crossed mutually for forming a square hole 5. To pass around conductive wire through the hole 5, being structured above, inhigh speed, a press-formed square wire is manufactured.

[0031] Total four rotation transmitting units are provided on respectiverollers 1-4 to rotate respective rollers 1-4 in high speed. Each of thefour rotation transmitting units includes a motor 6 and a synchronousbelt 8 for transmitting rotation of the motor 6 to a bearing unit 7.Each of the bearing units 7 is provided correspondingly with the firstroller 1, the second roller 2, the third roller 3 or the fourth roller4.

[0032] The four rotation transmitting units mentioned above are disposedin a shape of swastika around the hole 5 being formed by the firstroller 1-the fourth roller 4, as shown in FIG. 1. To place the fourrotation transmitting units in the shape of swastika, an area forinstalling the machine can be decreased and operatability of the machinecan be enhanced.

[0033] Furthermore, the square wire manufacturing machine according tothis invention has a position adjusting unit for fine-adjustingrespective disposed positions of the first roller 1, the second roller2, the third roller 3 and the fourth roller 4. The position adjustingunit being mounted on the third roller 3, shown in FIGS. 2 and 3, willbe described as a example.

[0034] The position adjusting unit being mounted on the third roller 3is provided with a set of two position adjusting devices. The set of twoposition adjusting devices is constituted by a first position adjustingdevice 9 for fine-adjusting the disposed position of the third roller 3to move the third roller 3 in a direction of an axis of the third roller3 and a second position adjusting device 10 for fine-adjusting thedisposed position of the third roller 3 to move the third roller 3 in adirection perpendicular to an axis of the third roller 3.

[0035] The first position adjusting device 9 is a wedge-slide-typeposition adjusting mechanism and includes a fixed wedge portion 11 and amovable wedge portion 12 being placed asymmetrically (in the oppositedirection) against the fixed wedge portion 11. The movable wedge portion12 is mounted on the bearing unit 7 and is energized always in adirection of an arrow A by a restoring force of a spring 13 to contactwith the fixed wedge portion 11 with pressure. The movable wedge portion12 is slid against the restoring force of the spring 13 by rotating amicrometer head 14. The third roller 3 is moved in a direction of theaxis thereof by sliding the movable wedge portion 12 so that thedisposed position of the third roller 3 is fine-adjusted.

[0036] The second position adjusting device 10 is a wedge-slide-typeposition adjusting mechanism, being constituted similarly as the firstposition adjusting device 9 and includes a fixed wedge portion 15 and amovable wedge portion 16 being placed asymmetrically against the fixedwedge portion 15. The movable wedge portion 16 is mounted on the bearingunit 7 and is energized always in a direction of an arrow B by arestoring force of a spring 17 to contact with the fixed wedge portion15 with pressure. The movable wedge portion 16 is slid against therestoring force of the spring 17 by rotating a micrometer head 18. Thethird roller 3 is moved in a direction perpendicularly to the axisthereof by sliding the movable wedge portion 12 so that the disposedposition of the third roller 3 is fine-adjusted. A wedge holding plate19 is provided.

[0037] Adjusting respective disposed positions of the first roller 1,the second roller 2, the third roller 3 and the fourth roller 4, whichhave respectively the position adjusting device 9 and the positionadjusting device 10 mentioned above, will be described with reference toFIG. 4. In FIG. 4, four rollers of the first roller 1-the fourth roller4 rotate respectively in a direction of an arrow C in high speed and apress-formed square wire is forwarded through the hole 5.

[0038] Firstly, the first roller 1 of the four rollers 1-4 is adjustedand fixed in a predetermined position. Thereafter, the second roller 2is fine-adjusted to have a gap (approximately 5 micron) against thefirst roller 1 by moving a disposed position thereof in a direction ofan axis thereof shown by an arrow D. Then, the second roller 2 isadjusted to have a forming size of a square wire to be manufactured bymoving the disposed position thereof in a direction perpendicular to anaxis thereof shown by an arrow F and fixed.

[0039] The third roller 3 is adjusted to have a forming size of a squarewire by moving a disposed position thereof both in a direction of anaxis thereof shown by an arrow G and in a direction perpendicular to anaxis thereof shown by an arrow H. The fourth roller 4 is fine-adjustedto have a gap (approximately 5 micron) against the first roller 1 bymoving a disposed position thereof in a direction perpendicular to anaxis thereof shown by an arrow J. Then, the fourth roller 4 is adjustedto have a forming size of a square wire by moving the disposed positionthereof in a direction of an axis thereof shown by an arrow K and fixed.

[0040] Thus, the disposed positions of the first roller 1, the secondroller 2, the third roller 3 and the fourth roller 4 can be adjustedfreely and minutely so that a thin square wire can be formed easily andprecisely. Changing a forming size can be done easily by a simpleoperation and then various sizes of square wires can be manufactured.

[0041] Having now fully described the invention, it will be apparent toone of ordinary skill in the art that many changes and modifications canbe made thereto without departing from the spirit and scope of theinvention as set forth herein.

What is claimed is:
 1. A square wire manufacturing machine comprising:four rollers being disposed in a shape of swastika to be crossedmutually for forming a square hole; and a position adjusting unit foradjusting disposed positions of the four rollers.
 2. The square wiremanufacturing machine according to claim 1, wherein the positionadjusting unit includes: a fixed wedge portion; and a movable wedgeportion contacting with the fixed wedge portion continuously withpressure and being disposed asymmetrically against the fixed wedgeportion, wherein the movable wedge portion is mounted on a bearing unitof the roller.
 3. The square wire manufacturing machine according toclaim 1, wherein the position adjusting unit includes: a first positionadjusting device for adjusting a disposed position of the roller to movethe roller in a direction of an axis of rotation of the roller; and asecond position adjusting device for adjusting a disposed position ofthe roller to move the roller in a direction perpendicular to the axisof rotation of the roller, wherein both the first and the secondposition adjusting devices are mounted on the bearing units ofrespective four rollers.
 4. The square wire manufacturing machineaccording to claim 2, wherein the position adjusting unit includes: afirst position adjusting device for adjusting a disposed position of theroller to move the roller in a direction of an axis of rotation of theroller; and a second position adjusting device for adjusting a disposedposition of the roller to move the roller in a direction perpendicularto the axis of rotation of the roller, wherein both the first and thesecond position adjusting devices are mounted on the bearing units ofrespective four rollers.
 5. The square wire manufacturing machineaccording to claim 1, wherein the position adjusting unit includes: afirst position adjusting means for adjusting and fixing a disposedposition of a first roller of the four rollers; a second positionadjusting means for adjusting a gap against the first roller to move adisposed position of a second roller in a direction of an axis ofrotation of the second roller and adjusting a forming size of the squarewire to move a disposed position of the second roller in a directionperpendicular to the axis of rotation of the second roller and fixingthe second roller; a third position adjusting means for adjusting a gapagainst the second roller to move a disposed position of a third rollerin a direction of an axis of rotation of the third roller and adjustingthe forming size of the square wire to move a disposed position of thethird roller in a direction perpendicular to the axis of rotation of thethird roller and fixing the third roller; and a fourth positionadjusting means for adjusting the forming size of the square wire tomove a disposed position of a fourth roller in a direction of an axis ofrotation of the fourth roller and adjusting a gap against the firstroller to move a disposed position of the fourth roller in a directionperpendicular to the axis of rotation of the fourth roller and fixingthe fourth roller.
 6. The square wire manufacturing machine according toclaim 2, wherein the position adjusting unit includes: a first positionadjusting means for adjusting and fixing a disposed position of a firstroller of the four rollers; a second position adjusting means foradjusting a gap against the first roller to move a disposed position ofa second roller in a direction of an axis of rotation of the secondroller and adjusting a forming size of the square wire to move adisposed position of the second roller in a direction perpendicular tothe axis of rotation of the second roller and fixing the second roller;a third position adjusting means for adjusting a gap against the secondroller to move a disposed position of a third roller in a direction ofan axis of rotation of the third roller and adjusting the forming sizeof the square wire to move a disposed position of the third roller in adirection perpendicular to the axis of rotation of the third roller andfixing the third roller; and a fourth position adjusting means foradjusting the forming size of the square wire to move a disposedposition of a fourth roller in a direction of an axis of rotation of thefourth roller and adjusting a gap against the first roller to move adisposed position of the fourth roller in a direction perpendicular tothe axis of rotation of the fourth roller and fixing the fourth roller.7. The square wire manufacturing machine according to claim 3, whereinthe position adjusting unit includes: a first position adjusting meansfor adjusting and fixing a disposed position of a first roller of thefour rollers; a second position adjusting means for adjusting a gapagainst the first roller to move a disposed position of a second rollerin a direction of an axis of rotation of the second roller and adjustinga forming size of the square wire to move a disposed position of thesecond roller in a direction perpendicular to the axis of rotation ofthe second roller and fixing the second roller; a third positionadjusting means for adjusting a gap against the second roller to move adisposed position of a third roller in a direction of an axis ofrotation of the third roller and adjusting the forming size of thesquare wire to move a disposed position of the third roller in adirection perpendicular to the axis of rotation of the third roller andfixing the third roller; and a fourth position adjusting means foradjusting the forming size of the square wire to move a disposedposition of a fourth roller in a direction of an axis of rotation of thefourth roller and adjusting a gap against the first roller to move adisposed position of the fourth roller in a direction perpendicular tothe axis of rotation of the fourth roller and fixing the fourth roller.8. A square wire manufacturing machine comprising: four rollers beingdisposed in a shape of swastika to be crossed mutually for forming asquare hole; and four rotation transmitting devices including motors fordriving respectively the four rollers, wherein the four rollers and thefour rotation transmitting devices are disposed in the shape of swastikaaround the hole.